INSTALLATION & OPERATING INSTRUCTIONS for
Contents
1. CONNECTOR 950356 Plasma Gas N2 Connection Cooling Gas Connection GAS HOSE 12 1 2 ft 40V77 e R 27 75 320 CO REGULATOR 17855m Set at 25 psig TR 21SP TRUCK lt AIR HOSE 678152 POS NEG CO2 HEATER INPUT POWER CABLE 950578 See Sect IV B amp Fig 2 opt AIR SUPPLY 150 psig max Ss Customer supplied v A X E w Mtg Brkt WORK CABLE 678006 25 or 678007 507 See Sect IV C 2 f for IMPORTANT safety information Supplied with Nitrogen Cooling Outfits u Supplied with CO Cooling Outfits TR 21 UPPER CYL RACK e Supplied with Air Cooling Outfits SAFETY e NOTE PT 121M Mechanized torch uses a separate remote hand controlled torch switch GROUND 2075600 supplied with each mechanized outfit See Sect II B 1c for mounting See Sect IV C 2 g equipment required S Fig 4 Interconnection Diagram PCM 70 PT 121 9 Nitrogen to PLASMA GAS fitting nitrogen air or CO2 to COOLING GAS fitting Connections should be wrench tight f Electrically connect work cable to work piece The connection must be made to a clean exposed metal surface free of paint rust mill scale etc WARNING A poor connection or failure to connect work cable to Work piece can result in fatal shock g Make sure workpiece is connected to an approved earth ground Use copper ground cable equal to or larger than the power supply chassis ground listed in Table 6 V ADJUS2. to prevent accidental shocking Take care not to connect the ground wire to any of the primary leads 4 Recheck all connections to make sure that they are tight well insulated and that the proper connection has been made Then reinstall the access door to right side panel CUSTOMER S FUSEDLINE DISCONNECT SWITCH See Table 6 for fuse size INPUT TERMINAL BOARD TB See below 4 COND CABLE 32 or 3 COND CABLE 1 Customer Supplied See Table 6 JUMPER DOUBLE LINKS 3 SETS TB 3 Phase Unit Fig 2 Input Power Cable Connection and Terminal Board TB C SECONDARY OUTPUT CONNECTIONS Before making any connections to the power supply out put terminals make sure that all primary input power to the machine is deenergized off at the main disconnect switch 1 Using PT 17A Torch Refer to Fig 3 a Connect the terminal lug end of the work cable as sembly to the WORK terminal in lower left corner of front panel Nut should be wrench tight b Lift front top cover to gain access to the torch connec tions c Connect pilot arc adaptor P N 19497 supplied with torch spare parts kit P N 680784 to the POS output fitting note that threads are left handed and tighten firmly with a wrench Loosely place screw washer and lockwasher in the most convenient tapped hole in the adaptor Thread the three torch service lines through the bushing in the upper left corner of the front
3. 032 Dia 30 Amps 1 32 3S 2F 1F iG 3G G ve 2E 3E 3E P N 17184 1 16 3F 1G 2G SS 3G 1G 2G 2E 1E 3G 1 8 3F 1G 2G 2G 1G 3F 1E 2G 39 0 047 Dia 70 Amps 1 32 2G 1E 3G 3G 2G 1G 2G 3G 1E P N 999279 1 16 1G 2G 3F 1G 2F 3F 1G 2G 3G 1 8 3F 1G 2G 1G 3F 2G 1E 2G 3G e 3 16 3F 2G 1G 3S 2F 1F 3G 1E 2E 1 4 3F 1G 2G 4F 3S 1F 2F 4F 2F 1G 3S 1E 1 2 3S 1F 2F 1F 3S 1F 2S 1F 28 1F 3S 1E 3 4 1F 1F 1E S S a ol E Excellent Essentially no bottom dross excellent cut face G Good Moderate to no bottom dross good cut face F Fair Heavier but removable bottom dross or fair cut face S Sever Heavy tenacious dross or poor face Numbers indicate order of cooling gas preferred for a particular material and thickness 6 C OPTIONAL ACCESSORIES 1 Drag Type Shield Guard P N 19989 PT 17A Protects the heat shield and permits the operator to drag a manual torch on the plate while cutting Thus main taining a fixed stand off tip to work distance throughout the cut resulting in a uniform appearance of the cut edge Two drag type guards are supplied with each spare parts kit 2 Standard Shield Guard P N 19990 non drag type PT 17A Protects the shield against accidental breakage on both manual and mechanized torches One standard guard is supplied with each spare
4. 5 With OPERATE SET UP switch in SET UP position gas solenoid valves should be open Adjust the gas regulator s to deliver proper pressure Tables 3 amp 4 6 Allow the gases to flow for a few minutes This should remove any condensation that may have accumulated during shut down 7 Place the OPERATE SET UP switch in the OPERATE position This will shut offthe gas flows The Low Gas will remain on It will go off when torch switch is depressed and it will then function as a low gas indicator light C OPERATION ARNING Wear the usual protective gloves clothing and helmet Helmet with filter lens shade No 6 or 7 should provide adequate protection for your eyes Never touch any parts forward of the torch handle tip heat shield electrode etc unless the Power switch is in the OFF position 1 Position the PT 17A or PT 121 torch on the workpiece by resting the heat shield on the edge of the workpiece where you intend to start the cut 2 Lower your protective helmet and then lift the torch about 1 8 in above the workpiece 3 Push down on the torch switch button mounted on the torch handle Pilot arc contactor and high frequency will energize and gas will start flowing Two seconds later the main contactor will come on The pilot arc should then transfer to the cutting arc NOTE If cutting arc does not start within 6 seconds the pilot arc will shut off Release torch switch Check to be sure gas pressures are ad
5. N 19499 282086 N d Xog 001 24911 N d Czo jueouqn 8uu O 899966 N d YUM diy L 992666 N d 1001 1Sn py 49 u82 L 0SMS8 N d Euu O 2818 9 ZLNOV 8 0 06S61 922666 62089 0 8089 009S202 SS ES Es 900829 200829 900829 100879 vvc666 Lvc666 9vc666 v 2666 009S70c 100879 Svc666 19cv09 992709 S9cv09 v9cv09 9cv09 z9Zv09 cVcvO9 Lbzv09 OvCtO9 6 cv09 8 cVv09 4 cv09 LLAOv 6c961 O6S61 922666 62089 0 8089 009S20 E 900829 200829 900829 4008 9 vvc666 Lvc666 9vc666 vc666 009SZ0c 400829 Svc666 L9cv09 092709 6Scv09 8Scv09 9S 0S6 ZLAOV 06S61 922666 62089 0 8089 0098S20c 900829 1008 9 900829 400879 vvc666 Lvc666 9vc666 vo666 0095202 200829 Svc666 UHM 2101 WLZL Ld peziueu2ew UuMuoJo01 WLZL Ld uim uo401 LZL Ld peziueuoeqw jenuew DU 06 VuM eBexoed eseug L 02 W2d 900829 cvc666 900829 cvc666 900879 cvc666 UA u2401 LCL Ld IenuenN PH GZ L6M96 26066 LS2666 N d 0095202 200829 Svc666 009SZ0c 100879 Svc666 0099202 1008 9 Svc666 98S666 N d 4eoeds OvS61 N d Weg L N d 6uu 0 2 092666 N d uesu Apog 1u013 L N d 6uu 0 S 029666 N d edA1 Beg peius 1eeH Z ded yoo 92666 N d PJepueiS pieius 16H 2918 9 LLNOV 8 0 O6S61 922666 62089 004089 009S202 x 900829 100879 900829 200829 900829 vvc666 Lvc666 972666 vc666 evc666 LLA
6. equipment until you have read and fully understand these Instructions If you do not fully understand these Instructions contact your supplier for further information Be sure to read the Safety Precautions on page 2 before installing or operating this equipment Be sure this information reaches the operator You can get extra copies through your supplier LTEC WELDING amp CUTTING SYSTEMS SAFETY PRECAUTIONS WARNING These Safety Precautions are for your protection They sum marize precautionary information contained in the references in item 7 and as noted herein Before performing any installation or operating procedures be sure to read and follow the safety precautions listed below as well as all other manuals material safety data sheets labels etc Failure to observe Safety Precautions can result in personal injury or death PROTECT YOURSELF AND OTHERS Some welding cutting and gouging processes are noisy and require ear protection Skin and eye burns from arc rays can be more severe than sunburn Hot metal can cause skin burns and heat rays may injure eyes Training in the proper use of the processes and equipment is essential to prevent accidents Also a Always wear safety glasses with side shields in any work area even if welding helmets face shields and goggles are also required b Use a face shield fitted with the correct filter and cover plates to protect your eyes face neck and ears from spar
7. panel and proceed as follows 1 Connect the power cable large male nut with left hand threads to the NEG output fitting and tighten firmly with a wrench 2 Connect pilot arc cable to the adaptor assembled on POS fitting at the most convenient tapped hole position of adaptor With washer and lockwasher in place tighten screw firmly with a screwdriver 3 Connect the 2 prong switch lead to the mating receptacle Make sure plug is firmly locked in place Close the top cover Assemble the filter regulator 30338 to the upper left corner on the rear panel view from rear as il lustrated Mounting holes are provided Hardware is supplied with the mounting bracket Connect the air hose assembly 678152 to filter regulator outlet fitting and to the Plasma Gas Air fitting on the rear panel of the PCC 70 unit Note that the air hose has left hand threaded nut on one end regulator and right hand on the other Connect your air supply to the inlet connection 1 4 in NPT female customer to supply suitable end fitting of the filter regulator Electrically connect work cable to work piece The connection must be made to a clean exposed metal surface free of paint rust mill scale etc WARNING A poor connection or failure to connect work cable to work piace can result in fatal shock j Make sure workpiece is connected to an approved earth ground Use copper ground cable equal to or larger than the power supp
8. this equipment does not operate properly stop work immediately and investigate the cause of the malfunction Maintenance work must be performed by an experienced person and electrical work by a trained electrician Do not permit untrained persons to inspect clean or repair this equipment Use only recommended replacement parts NOTE For detailed maintenance troubleshooting and parts information on the PCM 70 Console see Form 14 390 A INSPECTION AND CLEANING Frequent inspection and cleaning of the PCM 70 cutting machine is recommended Some suggestions for inspecting and cleaning are as follows WARNING Make sure the power is shut off 1 Check heat shield on torch It should be replaced if damaged 2 Check the torch electrode and cutting tip for wear on a daily basis Remove spatter or replace if necessary Make sure cable and hoses are not damaged or kinked 4 Make sure all plugs fittings and ground connections are tight 5 With all input power disconnected and wearing proper eye and face protection blow out the inside ofthe cutting power supply using low pressure dry compressed air e CAUTION Water occasionally accumulates in compressed air lines Be sure to direct the first blast of air away from the equipment to avoid damage 6 Occasionally bleed water from the filter beneath the air regulator B FLOW TESTING WARNING Avoid fatal shock Follow the steps below to assure safe flow measureme
9. 4 A 208 V 48 A 230 V 24 A 460 V Output Rating 65 duty Cycle 2 3 en ore bd SE Saas eet gen E Sn 70 A 100 V DCSP Open Circuit Voltage Nom 325 V DC 3 Ph 350 V DC 1 Ph ros E 76 3 Ph 88 1 Ph DIMENSIONS 3 10 vvcos cov ee PISO cR GRE E cee Peewee ae eee 35 high x 26 wide x 16 deep Welglit ie sencen weceaist chose dcateeas ix ru URS p4 SA 375 Ibs 3 Ph 345 Ibs 1 Ph Note the high open circuit voltage Use only torches designed for this equipment Do NOT attempt to use this equipment with any process other than plasma arc cutting PT 121 Torch Plasma Cutting Gas Nitrogen 9 25 psi 30 cfh or H 35 9 65 psi 100 cfh Secondary Cooling GaS sica cota beanies cosas ted peus Nitrogen or Air 25 psi 200 cfh or CO 9 25 psi 160 cfh Dimensions 8 9 16 in min 5 8 in 1 1 4 in 15 1 8 in max SS j 1 3 8 in Stud Satie eee yl 13 5 8 in 12 in 75 head illus 11 3 4 in 90 head 18 1 4 in Lengthiot Service DEE 25 or 50 ft Instruction Booklet EE Binh Sci Ebest Saco sat I AE Form F 12 794 PT 17A Torch Cutting Cooling Gas ue o Eege NEE AER eee ea PES Air 75 psi 290 cfh min Dimensions 8 3 16 MIN 14 3 4 MAX ER 5 8 stud E K EN q PT 17AM m 17 1 4 Shipping Wgt 9 Ibs 25 Sh Wat 101bs 25 A 151bs 50 ft iod ep s Length of Service Lines 22 4 eee ec ce ene ence
10. 5 psig 70Amps 1 4 in 116 140 200 250 P N 17119 Cooling Gas 25 psig 1 8 50 80 100 3 16 30 50 70 1 4 25 40 60 1 2 10 10 u 10 0 055 Dia Plasma N2 25 psig 70 Amps 1 4 in 1 16 175 220 240 P N 999263 Cooling Gas 25 psig 1 8 55 85 100 1 4 20 25 50 1 2 8 8 8 E 0 032 Dia Plasma H35 65 psig 35 Amps Conditions not developed P N 17184 Cooling Gas 25 psig 7 u 0 046 Dia Plasma H35 65 psig 70 Amps Conditions not developed o P N 17119 Cooling Gas 25 psig 0 055 Dia Plasma H35 65 psig 70Amps 1 4 in 1 4 35 40 80 E P N 999263 Cooling Gas Air 25 psig 1 2 10 15 18 3 4 5 3 10 x 0 046 cutting tip is supplied with Torch Spare Parts Kit 999276 0 055 cutting tip may be used in place of 0 047 tip for longer consumable life at 70 amps but with lower cutting speed NOTE The speed ranges given are typical for best quality cuts Results will vary depending on material composition surface conditions operator technique etc Also see Gas Selection Chart Table 5 for additional reference If cutting speed is too fast you may lose the cut On slow speeds dross may accumulate Table 5 Cooling Gas Selection Chart PCM 70 PT 121 Low Carbon Steel Stainless Steel Aluminum Cutting Current Mat Cooling Gas N2 Plasma H 35 Pla Cooling Gas N2 Plasma H 35 Pla Cooling Gas N2 Plasma H 35 Pla Tip Setting Thick N2 CO2 Air Air N2 CO Air Air N2 CO Ai Air 0
11. F 14 376 B INSTALLATION amp OPERATING F 14 376 B INSTRUCTIONS for March 1989 PCM 70 PLASMA ARC CUTTING PACKAGES I FEATURES cuts up to 3 4 thick material for greater versatility B power factor corrected version standard for low input draw B variable output provides greater versatility HW use of either a PT 17A torch for air operation or a PT 121 torch with choice of dual gases B perfect electrode centering gives longer torch and consumabies life W hinged top cover for easy maintenance W pilot arc starting delivers sure starts even on paint automatic intermittent cutting for grates and expanded metal B single and three phase models are available W five tips available for PT 17A for superior cutting per formance P CM 70 standard and drag type heat shield guards available for operator convenience W two year warranty parts information on the PCM 70 Console see NOTE For detailed maintenance troubleshooting and Qc va Form 14 390 v NOTE For listing of changes covered in the reprint of this booklet see page 12 These INSTRUCTIONS are for experienced operators If you are not fully familiar with the principles of operation and safe practices for electric welding equipment we urge you to read our booklet Precautions and Safe Practices for Electric Welding and Cutting Form 52 529 Do NOT permit untrained persons to install operate or maintain this equipment Do NOT attempt to install or operate this
12. O can also be used c Mechanized Torch PT 17AM or PT 121M Mounting and Travel Carriage A Torch Rigging Assembly P N 995984 see Form 14 390 is available for mounting the PT 17AM or PT 121M torch on a CM 79 or CM 37 travel carriage If using a CM 79 an adaptor assembly 490769 is also required H 35 35 Hydrogen 65 Argon gas mixture is an excellent plasma gas for cutting aluminum or thick steel It is usually considered over nitrogen in mechanized or production cutting due to its ability to cut thicker materials as well as cutting thick materials with higher speeds The H 35 also provides longer consumable life with less fume emission These advantages often outweigh the greater ex pense of the mixture If using the H 35 the following will be required If using the PT 17AM or PT 121M with the CM 86 Shape Cutting Machine an adaptor kit P N 600435 will be required This adaptor kit permits the torch head to be in line with the rotor head of the cutting machine R 77 75 350 Fuel Gas Regulator P N 998341 Fuel Gas Hose Assembly 12 1 2 ft P N 19414 The PT 17AM or PT 121M can also fit any standard L TEC torch holder designed for torches with 1 3 8 in diam barrel and 32 pitch rack on riggings of larger cutting machines such as CM 50 CM 100 and others See your L TEC representative for more details Table 1 Available PCM 70 PT 17 Shop Air Packages b Cooling Gas If not using nitrogen for cooling then e
13. OT 62961 O6S61 922666 62089 002089 0099202 900879 200829 900829 200829 900829 vyc666 Lvc666 972666 vc666 cvc666 LSzvo9 9sevo9 otzvoo Lud vtzvO9 eezrog eoe a N d 9S 0S6 LLNOTY 06561 922666 62089 002089 009S20 900829 200829 900829 200829 900829 vvc666 Lvc666 9vc666 v2666 cvc666 YUM 9401 L t La IEIUGW PH 06 UA abexdeq eseug c 07 WOd IenueW PH GZ seBexoed sen jend LZL Ld 07 WOd 9IQelleAy Z ejqe p YUM 2401 LZL Ld 6SZ666 N d 991109 t 82 S402 N d epouioer3 Z 40 xa 6LLZL N d 26070 diL Bung z Sued 4910 LZ Ld Buwoloj y surejuoo 9 2666 N d Y SUB exeds 490101 UI O SOH Ju H Z L Z L OSOH seo pug Bim 10enbay 134 4 JV Joye nBay N 08S 08 22 4 1 sued exedg uo101 Wal O 99n11 dSEZ HL eseug 10 Addng 1e og 02 00d age Y GZ YAMS 01 U00 pueH Y 0 10 SZ ejqe OM YOL WLZL 40 LZL 1d sepnjoul oDexoeg 002 Jy H Z L Z esoH seo zZ doyeinBay 709 02 S4 2 H 10je n69H CN 089 S4 42 H 1 Sed eedg Yoo Ia IAD 8 ANIL dS LZ HL eseug 10 Aiddng 1 MOd 04 00d age y S2 YAMS 01 U00 pueH J 0S 10 SZ ej qeo HOM u9101 WLZL 40 LZL 1d Sepnjou obexoegd 1002 02 J0JO UUND A We L Z L OSOH seo Z JoyeinBay N 08S 0 44 H 1 Sueg eyedg YOO WH IAD 9 xoniL dS Le ul eseug 10 Aiddng 1 MOd 07 20d ap Y GZ YMS 04 U0D pueH 08 10 SZ e qeo MOM uo9J0L WLZL 40 LZL 1d sep
14. TMENTS amp OPERATIONS CAUTION Never under any circumstances operate the power supply with the cover removed In addi tion to the safety hazard improper cooling may cause damage to internal components Keep side panels and top closed when unit is ener gized Also make sure you are adequately protected before you start cutting protective helmet and gloves should always be worn Refer to page 2 for additional operating precau tions CAUTION Voltage is available at the POWER On Off switch on the hinged top cover when voltage is applied to the input terminal board even when the POWER switch is OFF A TORCH ADJUSTMENTS WARNING Before making any adjustments or performing any main tenance on the torch make sure the power to the torch is shut off and the Torch On light is off Do NOT make any adjustments underneath the hinged top of the unit unless the primary power to the unit is OFF even if the Power on off switch is off For torch adjustments see booklet F 12 794 PT 121 or F 14 441 PT 17A packed with the torch B PCC 70 ADJUSTMENTS 1 Slowly open the nitrogen and CO2 or air cylinders val ves 2 Place the PCC 70 OPERATE SET UP and POWER switches in the SET UP and OFF positions Place the primary wall switch in the ON position 4 Place POWER SWITCH to ON POSITION Low Gas light should light up This light is indicating that power is applied to the control circuit Fan should be running Wi
15. a Always provide adequate ventilation in the work area by natural or mechanical ventilation means Do not weld cut or gouge on materials such as galvanized steel stainless steel copper zinc lead beryllium or cadmium unless positive mechanical ventilation is provided Do not breathe fumes and gases from these materials b Do not operate in locations close to chlorinated hydrocarbon vapors coming from degreasing and spraying operations The heat or arc rays can react with solvent vapors to form phosgene a highly toxic gas and other irritant gases c If you develop momentary eye nose or throat irritation while operating this is an indication that ventilation is not adequate Stop work and take necessary steps to improve ventilation in the work area Do not continue to operate if physical discomfort persists d Referto ANSI ASC Standard Z49 1 in item 7 below for specific ventilation recommendations EQUIPMENT MAINTENANCE Faulty or improperly maintained equip f ment can result in poor work but most importantly it can cause physical l injury or death through fires or electrical shock Therefore Always have qualified personnel perform the installation troubleshoot ing and maintenance work Do not perform any electrical work unless you are qualified to perform such work b Before performing any maintenance work inside a power supply discon nect the power supply from the electrical power source c Maintain cables groundi
16. d cable or may be run in a solid or flexible conduit Refer to Table 6 for recommended input conductors and line fuse sizes Table 6 Recommended Sizes for Input Conductors and Line Fuses Rated Input Input amp Gnd Fuse Conductors Size Volts Phase Amps CU AWG Amps 230 3 38 8 60 460 3 19 12 30 208 1 54 EI 6 80 230 1 48 6 70 460 1 24 10 40 sx Sized per National Electric Code for 75 C rated conductors 30 C am bient Not more than three conductors in raceway or cable Local codes should be followed if they specify sizes other than those listed above 2 As shipped the PCC 70 is set up for 460 volt 60 hertz input If using 230 or 208 volt input the links on the terminal board TB and jumper on terminal block T1 inside the unit must be repositioned see Fig 2 To gain access to the terminal board remove access door on right side panel 3 Thread the input conductor cable from the wall discon nect switch through the strain relief hole in the rear panel to the input terminal board Connect the primary power leads to terminals L1 L2 and L3 if using 3 phase if single phase connect leads to L1 and L2 and the green ground wire to GND terminal on the terminal board using UL listed pressure wire connectors Secure the input cable by tightening the strain relief coupling CAUTION It is of the utmost importance that the chassis be connected to an approved electrical ground
17. e power supply by connecting a ground wire between the power supply and the ground system of the input power d eiis make sure that the workpiece is connected to a good electrical ground e Itis especially important particularly with plasma cutting equipment to be sure the work cable is connected to the workpiece A poor or missing connection could expose the operator or others in the area to a fatal shock f Do not use worn or damaged cables Do not overload the cable Use well maintained equipment g When not operating turn off the equipment Accidental overloading can cause overheating and create a fire hazard Do not coil or loop cable around parts of the body h Be sure the proper size ground cable is connected to the workpiece as close to the work area as possible Grounds connected to building framework or other remote locations from the work area increase the possibility of output current passing through lifting chains crane cables or various electrical parts i Keep everything dry including clothing work area cables electrode holder and power supply Fix water leaks immediately j Refer to ANSI ASC Standard Z49 1 in Item 7 below for specific grounding recommendations Do not mistake the work lead for a ground cable 4 FUMES AND GASES Fumes and gases particularly in confined spaces can cause discomfort and physical harm Do not breathe fumes and gases Shielding gases can cause asphyxiation Therefore
18. ene thea 25 or 50 ft Instruction Booklet Form F 14 441 Ill EQUIPMENT SUPPLIED amp ACCESSORIES Generally CO is the preferred cooling gas for cutting thick carbon steel and aluminum air for cutting thick A OUTFITS AVAILABLE stainless steel In cutting thin stock of any material Available outfits are listed in Tables 1 and 2 there is no significant difference in cutting speed or quality regardless ofthe cooling gas used 170 230 cfh B REQUIRED EQUIPMENT of Air or Nitrogen or 13 190 cfh of CO2 at 25 psig of 1 Using PT 17A Torch cooling gas is required for proper torch cooling a Air Supply Aminimum of 290 cfh ofair is required for the cutting cooling gas Clean dry air at a pres sure between 90 and 150 psi should be supplied to the inlet of the air filter regulator supplied with each PCM 70 PT 17A Packages 2 Using PT 121 Torch a Nitrogen or H 35 Gas Supply Nitrogen is most commonly used for plasma gas on the PT 121 torch A single cylinder can be used for both plasma and cooling by use of the Y connector on outlet of regulator NOTE When using CO2 as a cooling gas at least 4 cylinders should be manifolded or a high capacity CO2 heater may be employed to prevent freeze ups or dry ice formation at the regulator If using H 35 for plasma gas air and CO2 produce the least dross and are recommended for low carbon and stainless steels Nitrogen produces the smoothest face on aluminum but air or C
19. equate work cable is firmly connected to workpiece torch was about 1 8 to 1 4 in above workpiece etc Then start from step 1 again 4 For manual cutting maintain a standoff torch to work distance of about 1 8 to 3 8 in 3 16 to 1 4 in with the PT 121 See Table 3 or 4 Keep the torch head vertical and move it at a rate that produces the desired cut quality The cutting should produce a straight fine spray of molten metal emitting from beneath the workpiece as illustrated in Fig 5 For mechanized cutting see Table 3 or 4 for recommended cutting speed range 5 If cutting arc is lost during cut the pilot arcimmediately reignite as long as the torch switch is depressed You then have about 6 seconds to move the torch close enough to work to reestablish the cutting arc 6 The cutting arc will extinguish at the end of the cut however the torch switch should be released to keep the pilot arc from reigniting 7 When cutting operation is completed wait a few minutes before placing the POWER switch to the OFF too slow too fast correct Fig 5 Effect of Cutting Speed D position so that the cooling fan has time to remove the heat from the unit Then shut off the primary power at the main disconnect switch COMMON CUTTING FAULTS Listed below are common cutting problems followed by probable causes of each If problems are determined to be caused by the PCM 70 Console refer to the troubleshooting section in b
20. ipt of the unit Notify the carrier of any defects or damage at once 2 Check the container for any loose parts Check air pas sages on rear panel of cabinet for any packing materials that may obstruct air flow through the power supply 3 On PCM 70 PT 121 packages mount the components of the TR 21SP truck and cylinder kit 680793 as directed by F 14 414 packed with the kit 4 The machine components are maintained at proper operating temperatures by forced air which is drawn through the front panel louvers and holes in the base and out the rear panel by a heavy duty fan Locate the machine in an open area where air can circulate freely through the openings Leave at least two feet of clearance between the unit and wall or other obstruc tion The area around the unit should be relatively free of dust fumes and excessive heat B PRIMARY INPUT ELECTRICAL CONNECTION WARNING Precautionary measures should be taken to provide max imum protection against electrical shock Be sure that all power is off by opening the line wall disconnect switch and unplug the power cord to the unit when primary electrical connections are made to the power supply 1 A line wall disconnect switch with fuse or circuit breakers should be provided at the main power panel The primary power leads should be insulated copper conductors and include three power leads two if using single phase and one ground wire The wires may be heavy rubber covere
21. ither a cylinder of CO2 or a suitable supply of air 150 psig max will be required See Tables 4 and 5 PCM 70 Shop Air Package with 8 Phase Console 1 Phase Console PT 17A 75 Hd PT 17AM PT 17A 75 Hd PT 17AM Manual Torch Mechanized Torch Manual Torch Mechanized Torch 25 lines 50 lines 25 lines 50 lines 25 lines 50 lines 25 lines 50 lines PCM 70 Shop Air Pkg P N 604217 604218 604219 604220 604246 604247 604248 604249 includes PT 17A or 17AM Torch 19999 20000 20001 20002 19999 20000 20001 20002 Work Cable 25 or 50 ft 678006 678007 578006 678007 678006 678007 678006 678007 Hand Control Switch 25 ft cable 680982 680982 680982 680982 PCC 70 Console 3 or 1 Phase 680700 680830 Torch Spare Parts Kit 680784 680784 Air Filter Regulator w Mtg Brkt 30338 30338 Air Hose Assy 30 in 678152 678152 Torch Spare Parts Kit P N 20063 includes following PT 17 torch parts 1 Cutting Tip 0 052 P N 19916 Pkg of 5 1 Baffle Tube P N 19114 1 Shroud Cap P N 19498 1 Cutting Tip 0 046 P N 19915 Pkg of 5 3 Heat Shield Guard P N 19124 1 Adaptor Pilot Arc P N 19497 1 Cutting Tip 0 057 P N 19917 Pkg of 5 2 Shield Drag Type P N 19122 1 Wrench P N 19129 5 Electrode P N 19918 Pkg of 5 1 Shield Guard Std P N 19990 1 Tool Box P N 950272 1 Electrode Adaptor P N 20053 1 Shroud P
22. ks and rays of the arc when operating or observing operations WARN bystanders not to watch the arc and not to expose themselves to the rays of the electric arc or hot metal c Wear flameproof gauntlet type gloves heavy long sleeve shirt cuffless trousers high topped shoes and a welding helmet or cap for hair protection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be desirable as protection against radiated heat and sparks d Hot sparks or metal can lodge in rolled up sleeves trouser cuffs or pockets Sleeves and collars should be kept buttoned and open pockets eliminated from the front of clothing e Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains f Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can travel considerable distances Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from flames and arcs as well as their radiation can act as ignition sources Hot slag or sparks can also cause fires and explosions Therefore a Remove all combustible materials well away from the work area or completely cover the materials with a protective non flammable covering Combustible materials include woods cloth sawdust liquid and gas fuels solvents paints and coatings paper etc b Hot sparks or hot metal can fall through cracks or crevices in floors or wall
23. ly chassis ground listed in Table 6 2 Using PT 121 Torch Refer to Fig 4 a Connect the terminal lug end of the work cable as sembly to the work terminal at the lower left corner of front panel Lift front top cover to gain access to torch connections Thread the three service lines gas power and switch lead of the PT 121 torch through bushing in upper left corner of front panel and connect them to the matching fittings adjacent to the work terminal Hose connections should be wrench tight Make sure plug of the switch lead is firmly locked in place Then close the top cover Connect the gas supplies The cylinders may be placed and secured on the cylinder rack of the truck Before connecting the regulator s be sure to read understand and follow all instructions packed with each regulator Connect the gas hoses to the regulator s and to the proper fittings on the rear panel of the PCC 70 AIR FILTER REGULATOR 30338 AIR HOSE ASSY w mounting bracket 678152 AIR CONNECTION INPUT POWER CABLE See Sect IV B amp Fig 2 AIR SUPPLY 90 psig min 150 psig max customer supplied ADAPTOR 19497 includes SCREW No 10 24 WASHER No 10 WORK CABLE 678006 25 ei LOCKWASHER No 10 or 678007 50 SAFETY GROUND See Sect IV C 1 i See Sect IV C 1 j for IMPORTANT safety information R 27 75 580 N REGULATOR 17166 e Connection for alternate Set at 25 psig H 35 Plasma Gas Y
24. ng wire connections power cord and power supply in safe working order Do not operate any equipment in faulty condition d Donotabuse any equipment or accessories Keep equipment away from heat sources such as furnaces wet conditions such as water puddles oil or grease corrosive atmospheres and inclement weather e Keep all safety devices and cabinet covers in position and in good repair f Use equipment for its intended purpose Do not modify it in any manner CYLINDER HANDLING Cylinders if mishandled can rupture and violently release gas Sudden rupture of cylinder valve or relief device can injure or kill Therefore a Usethe proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder Do not use adaptors Maintain hoses and fittings in good condition Follow manufacturer s operating instructions for mounting regulator to a com pressed gas cylinder b Always secure cylinders in an upright position by chain or strap to suitable hand trucks undercarriages benches walls post or racks Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit c When notin use keep cylinder valves closed Have valve protection cap in place if not connected for use Secure and move cylinders by using suitable hand trucks Avoid rough handling of cylinders d Locate cylinders away from heat sparks or flame of a welding c
25. njoul oDexoeg 009 EN NOTES 1 Table 3 PT 17A AM Cutting Data for Carbon Steel ut Cutiing Amp Stand Air Tip Max o Pressure psig 0046 40 Up to ES 1 P N 19915 3 16 SC 00527 amp I8 75 z P N 19916 a 0057 85 3 16 5 16 75 H P N 19917 Ww 3 4 0 067 105 1 4 3 8 85 z P N 20056 I As a general rule the thinner material requires the T 1 2 least stand off Es 100 AMP c Lu Lr zl UO ege E SE tS sie EEE 250 JL 150 100 200 300 350 400 CUTTING SPEED IN MIN Lower standoffs produce superior cuts on thin materials Do not initiate arc with cutting tip touching the work 2 The speed ranges given are typical for best quality cuts Results will vary depending on material surface conditions operator technique etc If cutting speed is too fast you may lose the cut On slow speeds dross may accumulate If speed is too slow cutting arc may go out Air cutting typically produces a rough face on stainless steel and aluminum Table 4 PCM 70 PT 121 Cutting Data Cutting Pressure Current Material Cutting speed in min for Mech Cutting Tip Settings Settings Standoff Thickness Low Carbon Steel Stainless Steel Aluminum 0 032 Dia Plasma N2 35 psig 30 Amps 1 8 in 1 32 200 200 250 P N 17184 Cooling Gas 25 psig 1 16 100 100 150 1 8 40 40 75 0 046 Dia Plasma N2 2
26. nt 1 Shut off input power at the main disconnect switch 2 Lift the top lid of the PCM 70 and unplug the torch switch cord 3 Close the lid 8 9 Turn on the power at the main disconnect switch Place gas mode selector switch OSS in SET UP posi tion Place power ON OFF switch ROS to ON Check flow measurements with P N 19765 flow measur ing kit Place ROS switch to OFF Turn off power at main disconnect switch 10 Reconnect torch switch plug inside console LITERATURE CHANGES The A edition 6 87 of this booklet was printed to cover part number change on the hand control switch 2075600 to 680982 in the PCM 70 PT 17M Mechanized packages and change in PT 17 cutting tips and electrode for greater operating PT 121 Plasma Gas Flow No Arc Nitrogen 9 25 psig 30 cfh KEE EE ete Se parade ne 75 cfh PT 121 Cooling Gas Flow Nitrogen or Air 25 psig 0 0 e ee ee eee 200 cfh CO2 0 25 psigi isses ced ent ec rena aeie e 160 cfh PT 17 Total Air Flow 75 psig 290 cfh minimum life Old tips and electrode are interchangeable with the new parts The B edition 3 89 of this booklet was printed to cover change from PT 17 to an upgraded PT 17A which provides higher cutting speed and as a result cutting data was revised F 14 376 B 89 0813 3 89 2M Printed in U S A L TEC Welding amp Cutting Systems Box F 6000 Florence SC 29501
27. ooklet Form 14 390 ppo Ep em rap pp E P Insufficient Penetration a Cutting speed too fast b Damaged cutting tip c Improper gas pressure d Standoff too low Main Arc Extinguishes a Cutting speed too slow Dross Formation In some materials and thick nesses it may be impossible to get dross free cuts a Cutting speed too fast or too slow b Improper gas pressure c Faulty tip or electrode d Standoff too low Double Arcing Damaged Tip Orifice Low gas pressure Damaged cutting tip Loose cutting tip Incorrect electrode set back PT 121 Contact with work Heavy spatter Very low speed on thin plate neven Arc Incorrect electrode set back PT 121 Damaged cutting tip Electrode not straight or centered Partially plugged holes on front end insert of torch See PT 121 torch booklet F 12 794 Unstable Cutting Conditions a Incorrect cutting speed b Loose cable or hose connections c Electrode and or cutting tip in poor condition d Incorrect electrode set back PT 121 Main Arc Does Not Strike a Loose connections b Improper Stand off between torch and work 11 c Torch not over the work d Torch not properly adjusted 8 Poor Consumable Life a Improper gas pressure b Improper electrode set back c Check O ring on the front end insert of torch see PT 121 torch booklet F 12 794 Vi MAINTENANCE If
28. openings and cause a hidden smoldering fire or fires on the floor below Make certain that such openings are protected from hot sparks and metal c Do not weld cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors Do not do hot work on closed containers They may explode d Have fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use e After completing operations inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire Use fire watchers when necessary f For additional information refer to NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes which is available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 ELECTRICAL SHOCK Contact with live electrical parts can cause severe burns to the body or fatal shock Severity of electrical shock is determined by the path and amount of current through the body Therefore a Never allow live metal parts to touch bare skin or any wet clothing Be sure gloves are dry b When standing on metal or operating in a damp area make certain that you are well insulated Wear dry gloves and rubber soled shoes and stand on a dry board or platform c Always ground th
29. parts kit 3 Drag Type Heat Shield P N 999620 PT 121 Slightly longer than a standard heat shield and slotted permitting the operator to drag a manual torch along the plate during a cut This maintains a fixed standoff tip to work distance throughout the cut providing a uniform appearance of the cut plate edge 4 Circle Cutting Attachment P N 19897 PT 17A P N 999696 PT 121 Permits cutting accurate circles from 4 1 2 in to 22 in in diameter with a manual torch The attachment includes a head and radius bar assembly center point adaptor and dual swivel castor assembly Cuts can be made inside or outside the circle The torch head is always held vertical during the cutting operation An accessory extension bar P N 163223 is also available for cutting larger circles up to 44 in in diameter The attachment is also handy for maintaining a constant standoff in other types of cutting 5 Plasma Gas Flow Measuring Kit P N 19765 This kit is used for checking gas flows through torch See Section VI B IV INSTALLATION Proper installation can contribute materially to satisfac tory and trouble free operation of the cutting outfit It is suggested that each step in this section be studied carefully and followed as closely as possible A INSPECTION AND PLACEMENT 1 Having removed the shipping container and before removing the skid inspect for evidence of concealed damage which may not have been apparent upon rece
30. utting or gouging operation Never strike an arc on a cylinder e For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 ADDITIONAL SAFETY INFORMATION For more information on safe practices for setting up and operating electric welding and cutting equipment and on good working habits ask your L TEC welding equipment supplier for a copy of Precautions and Safe Practices for Electric Welding and Cutting Form 52 529 The following publications which are available from the American Welding Society 550 N W LeJuene Road Miami FL 33126 are recommended to you a ANSI ASC Z49 1 Safety in Welding and Cutting b AWS C5 1 Recommended Practices for Plasma Arc Welding c AWS C5 2 Recommended Practices for Plasma Arc Cutting d AWS C53 Recommended Practices for Air Carbon Arc Gouging and Cutting e AWS C5 5 Hecommended Practices for Gas Tungsten Arc Welding f AWS C5 6 Recommended Practices for Gas Metal Arc Welding g AWS SP Safe Practices Reprint Welding Handbook Vol 1 8th Edition SPI SPECIFICATIONS PCC 70 Console Input Voltage 3 Phase Model 230 460 V 60 Hz 1 Phase Model 9 ose RR mm ei ENEE ER PEE 208 230 460 V 60 Hz Input Current rated load 3 Phase Model 38 A 230 V 19 A 460 V T2PNASC 22 252 o rice ERES 5
Download Pdf Manuals
Related Search